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Transcript
Application Note
AN 16-002
Revision:
00
Issue date:
2016-08-22
Prepared by:
Rainer Weiss
Approved by:
Peter Beckedahl
Keyword: isolation, insulation, dielectric, high voltage, test
High voltage testing
1. General .....................................................................................................................................1
1.1 High voltage type test ............................................................................................................1
1.2 High voltage routine test ........................................................................................................2
2. High Voltage Testing ...................................................................................................................2
2.1 Test equipment .....................................................................................................................2
2.2 Test conditions......................................................................................................................2
2.3 Tested insulation ...................................................................................................................2
2.4 Test procedure ......................................................................................................................3
2.5 Test voltage level ..................................................................................................................7
2.6 Test failures .........................................................................................................................8
3. Differentiation to other Isolation Tests ..........................................................................................9
3.1 Impulse voltage test ..............................................................................................................9
3.2 Partial discharge test .............................................................................................................9
3.3 Insulation resistance test .......................................................................................................9
1.
General
The goal of most electrical industry standards is to protect the user of equipment from electrical danger.
For this purpose safety requirements for design and production have been established. Testing is used to
evaluate these requirements. The most important test is the high voltage test. It is known by a number of
names such as dielectric (strength) test, dielectric voltage-withstand test, flash test, high potential
(“HiPot”) test or isolation test.
1.1
High voltage type test
The proof of the design is done in a conformance (type) testing: A high voltage is used to verify that the
clearances and solid insulation of components have adequate dielectric strength to resist expected
overvoltage conditions [3]. It also shows that the equipment is able to work safely over its complete
lifetime. During the test the electrical stress on the insulation over its complete lifetime is simulated in a
very short time. Here it is assumed that the failure mechanism during lifetime is the same as in the test.
Using an empirical equation the lifetime stress is transferred to a test condition [4][5].
This empirical equation is used in some standards to determine the high voltage type test conditions with
an exponent of n=6. Typically the test voltage is calculated for an expected lifetime of 20 years. So
equipment with an operating voltage of 230V has to be high voltage tested with a voltage of 3400V for one
minute.
This also means that the examined insulation is aged completely during the type test and cannot be used
anymore. Therefore samples from high voltage type tests have to be scrapped or at least not be used if the
safety of the user will be affected.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 1/11
1.2
High voltage routine test
The test conditions of a type test therefore cannot be used in a routine test. It is not the goal of a routine
test to check if the equipment design is suited for the expected electrical stress on the insulation. Routine
tests are carried out only to verify that clearances and solid insulation have not been reduced or damaged
during the manufacturing operations or weak materials were used. To make sure that all insulation-related
production failures can be excluded the high voltage routine test is done when production is completed and
the equipment does not need to be reopened again. The test is not carried out to verify the insulation of
the elementary components and also the creepage distances [6].
The specification of a routine test must be strong enough that safety-relevant failures are detected but only
minimum ageing of the device occurs. Typical routine test specifications show that less than 0.000001% of
the lifetime are aged by the test under the assumption that the empiric equation from 1.1 is valid.
If, for any reason, it is necessary to repeat the high voltage test, the level of voltage for the second test
shall take into consideration that the high voltage test affects the quality of the insulation. Several
standards recommend reducing the voltage to 80% [3] or 85% [6][7] of the first test level. High voltage
tests with component data sheet values shall be avoided as well as routine incoming inspection tests.
The typical test periods of high voltage routine test are 1s or 5s. Though occasionally longer test periods
like 60s are specified. For semiconductor devices UL1557 describes the possibility to shorten the test period
by increasing the test voltage. The rated voltage with a test time of 60s is increased to 120% for 1s [8].
The test conditions for the SEMIKRON high voltage test are given in the datasheet (typically with the Visol
parameter). If the given test duration is 5s or 60s it is the type test condition. Shorter test durations like 1s
and 3s are routine test conditions.
2.
2.1
High Voltage Testing
Test equipment
Several suppliers offer high voltage test equipment. The main differences are

the maximum applied voltage,

the maximum applied current and

the options of a.c. and d.c. voltage.
More or less all available instruments fulfill the requirements for test equipment specified in EN 61180 [9].
Besides the voltage quality it is recommended that the short-circuit output current of the equipment is not
less than 200mA [10]. For UL a transformer with at least 500VA is enough to sustain the voltage during the
test [8].
2.2
Test conditions
Normally the high voltage test is performed with a sinusoidal voltage at 50Hz or 60Hz. If the circuit
contains capacitors the test may be performed with a d.c. voltage equal to the peak value of the specified
a.c. voltage . The d.c. voltage test is not fully equivalent to the a.c. voltage test due to the different
withstand characteristics of solid insulation for these types of voltages [10]. The polarity of the test voltage
has an impact on the flashover voltage. For d.c. tests it is necessary to check both polarities [4].
Semiconductor modules with large base plates can have relatively large capacitances (up to ≈10nF)
between both sides of their substrate. For these modules d.c. tests are recommended.
The d.c. high voltage test is advised for production facilities. A d.c. current is less risky for the human heart
in case of an accident. Additional workplace safety measures are not needed during high voltage testing
with a.c. up to 3mA and d.c. up to 12mA [11]. The d.c. high voltage test, thus, has the advantage that no
extra precautions are required for tests of 12mA or less. If the current is higher a special test room or a
sealed off area with warning light and two-handed operation is required in many countries.
A few standards request specified ambient conditions for the high voltage test. Typical values are 15C to
35C ambient temperature, 45% to 75% relative humidity and an air pressure of 860hPa up to 1060hPa.
2.3
Tested insulation
Test samples can contain several circuits which may be galvanically isolated from each other. The
insulation within and between these circuits is categorized for safety requirements:

Functional insulation separates potentials within a circuit and considers purely functional, but not
safety relevant aspects. [12]

Basic insulation separates grid supplied circuits from earthed exposed parts and is thus vital for
safety. A breakdown of the insulation does not result automatically in a danger of life due to the
earthing of the exposed parts [12]

Protective separation realized by reinforced or double (two times basic) insulation separates grid
supplied circuits from unearthed exposed parts, on the one hand, and from control circuits, if they
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 2/11
are directly connected to other control circuits which have exposed components. No further
protection is provided for equipment users. A breakdown of this insulation could be fatal because
the unearthed exposed parts can be shifted to the grid voltage. This is the reason why stricter
safety requirements must be fulfilled. [12]
The high voltage test is applied only on safety-relevant basic insulation and protective separation. Non
safety-relevant functional insulation is not tested.
2.4
Test procedure
Most standards for electrical equipment demand the following conditions for the test:

External terminals of the circuit shall be connected together.

Switchgear and controls within equipment shall be in the closed position or bypassed.

Terminals of voltage blocking components (such as rectifier diodes) shall be connected together.
It is mandatory to connect all test sample terminals of the same circuit with each other for the high voltage
test. These are the a.c. and d.c. terminals of the converter shown here [Figure 1].
Figure 1: Connecting of all terminals of a converter for the high voltage test
d.c.-
d.c.+
terminal connections for high voltage test
rectifier diode(s)
brake
chopper
IGBTdrivers
IGBT module(s)
current
sensor
optocoupler
grid
input
motor
output
a.c.: U
a.c.: L1
a.c.: L2
chopper
a.c.: L3
transformer
a.c.: V
optocoupler
a.c.: W
transformer
heatsink
heatsink
converter metal housing
V
high voltage
test equipment
If the test sample consists of more circuits which are isolated from each other with basic insulation or
protective separation it will be necessary to test all circuits to their surroundings. The meaning of
“surroundings” here is all adjacent circuits plus earth. Non earthed conductive parts that can be touched
are separate circuits by definition. Circuits with the same test voltage can be connected and tested
together. However more than one high voltage test may be necessary for the test sample.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 3/11
The connection of circuits may be different for type and routine tests if they require different test voltages.
Figure 2: Connecting of separate circuits of a converter to minimize the number of high
voltage tests
d.c.-
d.c.+
terminal connections for high voltage test
rectifier diode(s)
brake
chopper
IGBTdrivers
IGBT module(s)
current
sensor
optocoupler
motor
output
grid
input
a.c.: U
a.c.: L1
transformer
a.c.: L2
chopper
a.c.: V
optocoupler
a.c.: L3
a.c.: W
transformer
heatsink
fieldbus
interface
controller
supply
voltage
IGBT driver
supply voltage
heatsink
PWM signals
drive controller
converter metal housing
V
high voltage
test equipment
The power circuit is connected with the grid and has basic insulation to earth. The green circuit shown here
is for the drive control [Figure 2]. It has protective separation from the power circuit. The voltage between
drive control circuit and earth is below 50V. So the control circuit and earth can be connected with each
other for the high voltage test if the test voltage and the test duration for basic insulation and protective
separation are the same. If the test voltage level is different both circuits have to be tested separately.
The temperature sensor of power modules normally has only functional insulation to the power circuit
unless stated differently in the product datasheet. This means that for high voltage testing the sensor shall
be connected to the power circuit. If it is connected with the drive controller circuit and passes the high
voltage test it is not valid to conclude that the insulation between sensor and power circuit fulfills the needs
of protective separation.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
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If the requirement of connecting all terminals with each other is not followed semiconductors may be
damaged in case of a test fault. The voltage level in the test is usually higher than the blocking voltage of
the semiconductor. So the test voltage exceed the device (e.g. diode) voltage rating when the insulation
fails anywhere in the d.c. link and the test voltage supply is connected to an a.c. terminal only. In this
example the full test voltage is connected to the diode and causes it to fail as a result of the disconnected
d.c. terminals [Figure 3].
Figure 3: Semiconductor overvoltage in case of an isolation fault in high voltage test
d.c.-
rectifier diode(s)
d.c.+
brake
chopper
IGBTdrivers
IGBT module(s)
current
sensor
optocoupler
motor
output
grid
input
a.c.: U
a.c.: L1
a.c.: L2
chopper
a.c.: L3
transformer
a.c.: V
optocoupler
a.c.: W
transformer
heatsink
heatsink
converter metal housing
V
high voltage
test equipment
Surge protective devices must be disconnected before high voltage testing. If capacitors with high
capacitance are parallel to the parts between where the test voltage needs to be applied, it may be
difficult, or even impossible, to perform the a.c. voltage test because the charging current would exceed
the capacity or current set point of the voltage tester. In the latter case, those parallel capacitors could be
disconnected before testing. If this is also impossible, d.c. testing can be taken into consideration [10].
Table 1 gives an overview of the requirements for the high voltage test of the most relevant standards for
power electronics:

drives [3][23]

uninterruptible power systems (UPS) [13]

photovoltaic power systems [14]

power installations [7][10][15][16][22]

railway applications [6][17]

information technology [18]

power semiconductors [8][20]
The data of Table 1 is valid for basic insulation with voltages up to 1000V.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 5/11
Table 1: Overview high voltage test conditions of several standards
connection
of all
terminals
disconnection of
components
EN 50124-1
[17]
shall
-
EN 50178
[15]
optional
EN 60664-1
[10]
shall
-
EN 60747-15
[20]
shall
-
IEC 60950-1
[18]
optional
EN 61287-1
[6]
shall
EN 61439-1
[7]
shall
EN 61800-5-1
[3]
shall
forbidden for capacitors, permitted for
voltage sensitive device
like semiconductors
voltage
type
failure criteria
a.c. or
d.c. *
5s
no sparkover or
breakdown
a.c. or
d.c.
60s type
5s routine
no puncture,
flashover or
sparkover
a.c. or
d.c. * in
both
polarities
3 cycles for
a.c.
10ms for
d.c.
no puncture or
breakdown
-
permitted for:
-discharge resistors,
-filter capacitors,
-voltage limiting
devices,
-surge suppressors
test time
-
test current below
specified level
a.c. or
d.c. *
60s type
1s routine
a.c. or
d.c. *
60s type and
routine
forbidden for capacitors
a.c.
5s type
1s routine
no puncture, flashover or sparkover
permitted for protective
device, monitoring
circuit, semiconductors
a.c. or
d.c.
5s type
1s routine
no electrical
breakdown
-
EN 62040-1
[13]
Current increases
rapidly in an
uncontrolled manner. Corona
discharge or single
momentary
flashover is no
failure. [5.2.2]
-
same as IEC 60950-1
EN 62109-1
[14]
shall
permitted for protective
device, monitoring
circuit, semiconductors
a.c. or
d.c. *
5s type
1s routine
no electrical
breakdown
IEC 62477-1
[16]
shall
permitted for protective
device, monitoring
circuit, semiconductors
a.c. or
d.c. *
60s type
1s routine
no electrical
breakdown
UL 1557
[21]
shall
-
a.c.
60s type and
routine or 1s
120%
routine only
no breakdown
UL 1741
[22]
optional
-
a.c. or
d.c. **
60s type and
routine
no breakdown
UL 61800-5-1
[23]
shall
a.c. or
d.c. **
60s type
no
routine
test
no electrical
breakdown
permitted for protective
device, monitoring
circuit, semiconductors
* equal to peak voltage of a.c.
** equal 1.414 times voltage of a.c.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 6/11
2.5
Test voltage level
The voltage level in the high voltage test is determined by the operating voltage of the equipment. For this
the grounding of the connected grid is important. In a star grounded (TN) grid the voltage stress for the
insulation is lower (e.g. 230V in a 3-phase system with 400V line-to-line voltage) than in an corner
grounded grid with the same line-to-line voltage (here 400V).
In Table 2 the a.c. test voltage levels for basic insulation in equipment connected to a star grounded grid
are shown according to the most relevant standards for power electronics. Also given are the levels for
type tests and routine tests for typical grid voltages.
Table 2: Overview high voltage test a.c. levels for basic insulation of equipment for star
grounded grids in several standards
formular for test
voltage calculation
EN 50124-1 [17]
EN 50178 [15]
EN 60664-1 [10]
230V+10%
EN 61287-1 [6]
EN 61439-1 [7]
EN 61800-5-1 [3]
690V+10%
type
routine
type
routine
type
routine
1390V
1043V
2210V
1658V
3320V
2490 V
1.5 · U + 750V
-
EN 60747-15 [20]
IEC 60950-1 [18]
480V+10%
1133V
1470V
1900V
2065V
3482V
5222V
see endproduct standard
-
1500V
2 · Upeak/√2 + 1000V
1350V
2500V
1506V
-
-
U + 1200V
4000V
1610V
2000V
1453V
EN 62040-1 [13]
2250V
-
3600V
1880V
2500V
1505V
-
3000V
1640V
same as IEC 60950-1
EN 62109-1 [14]
U + 1200V
1453V
1505V
1640V
IEC 62477-1 [16]
U + 1200V
1453V
1505V
1640V
UL 1557 [21]
UL 1741 [22]
UL 61800-5-1 [23]
specified isolation voltage of product
2 · U + 1000V
-
1460V
-
1960V
-
2380V
-
1460V
-
1960V
-
3553V
-
The voltage level spread between the standards is wide (more than a factor of 3). The goal of the
semiconductor module manufacturer is to specify the isolation rating of the modules so high that it
matches the requests of all relevant standards. This is much higher what most applications need.
Test voltage levels for safety insulation can differ from these values considerably. In general they are
higher for the type test.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 7/11
Table 3: Overview of high voltage test a.c. levels for protective separation of equipment for
star grounded grids
230V+10%
EN 50124-1 [17]
480V+10%
690V+10%
type
routine
type
routine
type
routine
2210V
1658V
3500V
2625V
4870V
3653V
EN 50178 [15]
1133V
1470V
1900V
EN 60664-1 [10]
4130V
6964V
10 444V
EN 60747-15 [20]
IEC 60950-1 [18]
see endproduct standard
3000V
EN 61287-1 [6]
EN 61439-1 [7]
EN 61800-5-1 [3]
2700V
5000V
1506V
4500V
8000V
1610V
7200V
1880V
-
2000V
-
2500V
-
3000V
2906V
1453V
3010V
1505V
3280V
1640V
EN 62040-1 [13]
same as IEC 60950-1
EN 62109-1 [14]
2906V
1453V
3010V
1505V
3280V
1640V
IEC 62477-1 [16]
2906V
1453V
3010V
1505V
3280V
1640V
UL 1557 [21]
specified isolation voltage of product
UL 1741 [22]
1460V
-
1960V
-
2380V
-
UL 61800-5-1 [23]
2906V
-
3010V
-
3280V
-
Semiconductor modules have no integrated protective separation. Therefore the test levels given here are
relevant for equipment testing only.
The test voltage must be increased continuously to the maximum level within a minimum time period.
Some standards define this time, e.g. 5s minimum time [10][17].
2.6
Test failures
Different words are used in the standards for defining the various failure modes:

An electrical breakdown is a failure of insulation under electrical stress when the discharge
completely bridges the insulation, thus reducing the voltage between the electrodes almost to zero
[3]

disruptive discharge: passage of an arc following dielectric breakdown [24]

sparkover: disruptive discharge in a gaseous or liquid dielectric [24]

flashover: disruptive discharge over the surface of a solid dielectric surrounded by a gaseous or
liquid medium [24]

puncture: disruptive discharge through a solid dielectric [24]
The failure criteria for the high voltage test vary in the different standards and also partially contradict each
other. The test is considered successfully passed if:

No disruptive discharge (sparkover, flashover or puncture) occurs [10]. A leakage current that is
monitored during the test is not exceeded.

No breakdown [21] or insulation breakdown [3] occurs.

The test current doesn´t increase rapidly in an uncontrolled manner. Corona discharge or a single
momentary flashover is not regarded as insulation breakdown [18].
Due to these differences the failure criteria of the product relevant standard must be taken into account. A
general failure criterion is not defined.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 8/11
3.
3.1
Differentiation to other Isolation Tests
Impulse voltage test
The impulse voltage test is intended to simulate overvoltages of atmospheric origin. It also covers
overvoltages due to switching of equipment. The test is successfully passed if no puncture, flashover, or
sparkover occurs [3]. It is used to verify that the clearances and solid insulation of components have
adequate dielectric strength. Advantage of this test is the very short test time what minimize the electrical
stress for the insulation. This prevents any ageing effect on the component.
Solid insulation has a different withstand characteristic compared to clearance if the time of stress is
increased. In general the withstand capability will be decreased significantly. Therefore the high voltage
test, which is specified for the verification of the withstand capability of solid insulation, is not allowed to be
replaced by an impulse voltage test. The impulse voltage test is not able to check if the insulation of
components will work safely during the complete lifetime as in the high voltage type test.
3.2
Partial discharge test
The partial discharge test must confirm that the solid insulation used in components and subassemblies
remains partial-discharge-free with the specified voltage range [3]. Partial discharges in clearances which
do not result in breakdown are disregarded [10]. This test does not detect sparkover and the test level is
normally lower than overvoltages what can be expected from atmospheric origin.
Partial discharge tests for solid insulation must be specified if the applied peak value exceeds 700V and if
the average field strength is higher than 1kV/mm [10].
3.3
Insulation resistance test
The measurement of the insulation resistance is done to evaluate the general condition of the insulation. It
is normally made during regular maintenance and any additional ageing effect from testing should be
prevented. The measurement result gives an indication of ageing of the insulation by comparison with
previous results (over a period of years) but no hint to weaknesses in the isolation system [19]. Reduced
clearances of equipment and consequential flashovers are not tested here due to test voltages being far
below expected overvoltages of atmospheric origin.
Only the impulse voltage test will detect unintended insulation weaknesses as well as the high voltage
routine test.
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 9/11
Figure 1: Connecting of all terminals of a converter for the high voltage test ...........................................3
Figure 2: Connecting of separate circuits of a converter to minimize the number of high voltage tests........4
Figure 3: Semiconductor overvoltage in case of an isolation fault in high voltage test ...............................5
Table 1: Overview high voltage test conditions of several standards .......................................................6
Table 2: Overview high voltage test a.c. levels for basic insulation of equipment for star grounded grids in
several standards ............................................................................................................................7
Table 3: Overview of high voltage test a.c. levels for protective separation of equipment for star grounded
grids ..............................................................................................................................................8
References
[1] www.SEMIKRON.com
[2] A. Wintrich, U. Nicolai, W. Tursky, T. Reimann, “Application Manual Power Semiconductors”, ISLE
Verlag 2015, ISBN 978-3-938843-83-3
[3] EN61800-5-1: 2008, “Adjustable speed electrical power drive systems – Part 5-1: Safety requirements
– Electrical, thermal and energy”
[4] Wolfgang Pfeiffer, “Isolationskoordination in Niederspannungsbetriebsmitteln”, VDE-Verlag 1998, ISBN
3-8007-2181-3
[5] Klecsztyn, S. E., “Formal theoretical foundation of electrical ageing of dielectrics”, IEEE Transactions on
Power Apparatus and Systems 100, 1981
[6] EN 61287-1: 2007-08, “Railway applications – Power converter installed on board rolling stock – part
1: Characteristics and test methods”
[7] EN 61439-1: 2012_06, “Low-voltage switchgear and controlgear assemblies – Part 1: General rules”
[8] UL 1557: 2011-12-29, “Electrically isolated semiconductor devices”
[9] EN 61180:2013-07, “High-voltage test techniques for low-voltage equipment – definitions, test and
procedure requirement, test equipment”
[10]EN 60664-1: 2008-01, “Insulation coordination for equipment within low-voltage systems – Part1:
Principles, requirements and tests”
[11]EN 50191: 2011-10, “Erection and operation of electrical test equipment”
[12]R. Weiss, “Insulation coordination”, SEMIKRON application note, AN1405 – rev02, Nuremberg, 2014
[13]EN 62040-1: 2013-11, “Uninterruptible power systems (UPS) – Part 1: General and safety
requirements for UPS”
[14]EN 62109-1: 2011-04, “Safety of power converters for use in photovoltaic power systems – Part 1:
General requirements”
[15]EN 50178: 1997, “electronic equipment for use in power installations”
[16]IEC 62477-1: 2012, “Safety requirements for power electronic converter systems and equipment Part 1: General”
[17]EN 50124: 2016-03, “Railway applicatians – Insulation coordination – Part 1: Basic requirements Clearances and creepage distances for all electrical and electronic equipment”
[18]IEC 60950-1: 2005-12: “Information technology equipment – Safety – Part 1: General requirements”
[19]IEC 2/1776/CD:2014, “Rotating electrical machines – Part 27-4: Measurements of insulation resistance
and polarization index on winding insulation of rotating electrical machines”
[20]EN 60747-15: 2010, “Semiconductor devices – Discrete devices – Part 15: Isolated power
semiconductor devices”
[21]UL 1557: 2011-12-29, “Electrically isolated semiconductor devices”
[22]UL 1741: 2010-01-28, “Inverters, converters, controllers and interconnection system equipment for
use with distributed energy resources”
[23]UL 61800-5-1: 2012-06-08, “Adjustable Speed Electrical Power Drive Systems – Part 5-1: Safety
Requirements - Electrical, Thermal and Energy”
[24]IEC 61000-2-14: 2007-01-31, “Electromagnetic comptibility (EMC) – Environment.- Overvoltages on
public electricity distribution networks”
© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
Page 10/11
Symbols and Terms
Letter Symbol
Term
hPa
hecto Pascal; 1hPa = 0,01N / m2 = 0,01kg / m · s2
Visol
SEMIKRON high voltage test voltage [Vrms] in type or routine test
A detailed explanation of the terms and symbols can be found in the "Application Manual Power
Semiconductors" [2]
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The information in this document may not be considered as guarantee or assurance of product characteristics
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applications, which may still vary depending on the specific application. Therefore, products must be tested for the
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© by SEMIKRON / 2016-08-22 / Application Note
PROMGT.1023/ Rev.5/ Template Application Note
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